BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to a sheet stacking apparatus and an image forming
apparatus.
Description of Related Art
[0002] Recently, a sheet stacking apparatus with a larger capacity for stacking discharged
sheets has been required not only with a larger capacity, but also with the capability
to stack sheets with high accuracy.
[0003] In a sheet stacking apparatus, it is conceivable that another sheet bundle is stacked
on a previously stacked sheet bundle in a different position. The reason that another
sheet bundle is stacked on the previously stacked sheet bundle is, for example, to
notify the user of the position of the boundary between the sheet bundles (i.e. different
print jobs).
[0004] Here, it is known that another sheet bundle stacked on the previous one can have
the sheet edges aligned by an aligning member so that alignment of the bundles is
improved. Japanese Patent Application Laid-Open No.
2002-179326 describes such a configuration, in which a sheet stacked on a previously stacked
sheet bundle is aligned at a position different to that of the sheet bundle previously
stacked by a pair of aligning members.
[0005] Figs 18A and 18B illustrate a configuration disclosed in Japanese Patent Application
Laid-Open No.
2002-179326. Figs 18A and 18B illustrates an operation of aligning members 801a and 801b when
a second sheet bundle F2 is stacked with a displacement with respect to the position
of a first sheet bundle F1. After a sheet of the second sheet bundle drops on the
first sheet bundle F1 in the condition that the center of the sheet is aligned with
the sheet feeding center, the aligning member 801a moves in a direction indicated
by the arrow Ja in Fig. 18B to jog the sheet edge for aligning. Note that the aligning
member 801b stands still even when the aligning member 801a is moving. The aligning
operation by the aligning member 801a is carried out every time a sheet drops on the
sheet bundle.
[0006] In Japanese Patent Application Laid-Open No.
2003-002524, a sheet is discharged on a stapled sheet bundle, and aligning members move to align
the discharged sheet. The aligning members move to align the sheet while it is being
laid on the stapled sheet bundle. The aligning operation is carried out every time
a predetermined number of sheets are discharged on the stapled sheet bundle so, that
unnecessary aligning operations can be eliminated.
[0007] In the configuration disclosed in Japanese Patent Application Laid-Open
2002-179326, aligning members (jogging members) are laid on the previously stacked sheet bundle
when aligning the edges of discharged sheets. Therefore when an aligning operation
is carried out while moving the aligning members, the uppermost sheet of the previously
stacked sheet bundle is fed together with the aligning member in association with
the movement of the aligning members, and thus the alignment of the previously stacked
sheets is disturbed. When the aligning operation is repeated, the amount of deviation
of the sheets is further increased.
SUMMARY OF THE INVENTION
[0008] The present invention has been developed in view of such circumstances and provides
a sheet stacking apparatus and an image forming apparatus that can achieve a steady
stack of sheets without disordering the alignment of a previously stacked sheet bundle,
even when sheet bundles are displaced from one another (staggered) and stacked.
[0009] According to a first aspect of the present invention, there is provided a sheet stacking
apparatus as specified in claims 1 to 8.
[0010] According to a second aspect of the present invention, there is provided an image
forming apparatus as specified in claim 9.
[0011] According to the present invention, the sheet stacking apparatus can reduce the disorder
of the alignment of sheets previously stacked on the tray and hence achieve a good
alignment of the previously stacked sheets.
[0012] Further features of the present invention sill become apparent from the following
description of exemplary embodiments with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Fig. 1 is a diagram illustrating a configuration of an image forming apparatus including
a sheet stacking apparatus according to an embodiment of the present invention.
[0014] Fig. 2 is a control block diagram of a controller provided in the above image forming
apparatus.
[0015] Fig. 3 is a flowchart illustrating a basic control of a stacker connected to an image
forming apparatus main body in the above image forming apparatus.
[0016] Fig. 4 is a diagram illustrating a configuration of a grouping portion provided in
the above stacker.
[0017] Fig. 5 is a diagram illustrating a configuration of a stacking portion provided in
the above stacker.
[0018] Fig. 6 is a diagram illustrating a configuration of the above stacking portion.
[0019] Fig. 7 is a sectional view taken along the line VII-VII of Fig. 5.
[0020] Fig. 8 is a diagram illustrating a configuration of a stack tray provided in the
above stacker.
[0021] Fig. 9 is a diagram illustrating a state when a shiftless mode of the above grouping
portion is selected.
[0022] Figs. 10A and 10B are diagrams illustrating a state when a shiftless mode of the
above stacking portion is selected.
[0023] Fig. 11 is a diagram illustrating a state when the shiftless mode of the above stacking
portion is selected.
[0024] Fig. 12 is a diagram illustrating an aligning operation of a sheet in a sheet conveying
direction by a leading edge stopper of the above stacking portion.
[0025] Fig. 13 is a diagram illustrating a state of the stacking portion when the above
stacking tray descends.
[0026] Fig. 14 is a first diagram illustrating a sheet stacking operation when a shift mode
of the above stacking portion is selected.
[0027] Fig. 15 is a diagram illustrating a state when the shift mode of the above grouping
portion is selected.
[0028] Fig. 16 is a diagram illustrating a malfunction when a shift mode of the above stacking
portion is selected.
[0029] Figs. 17A and 17B are second diagrams illustrating a sheet stacking operation when
a shift mode of the above stacking portion is selected.
[0030] Figs. 18A and 18B are diagrams illustrating a configuration of a conventional sheet
stacking apparatus.
[0031] Fig. 19 is a flowchart of an aligning operation of a first and second side stoppers
410, 420 in the shift mode.
DESCRIPTION OF THE EMBODIMENTS
[0032] An exemplary embodiment for carrying out the present invention will now be described
in detail referring to the drawings.
[0033] Fig. 1 is a diagram illustrating a configuration of an image forming apparatus including
a sheet stacking apparatus according to an embodiment of the present invention.
[0034] In Fig. 1, an image forming apparatus main body 901 of an image forming apparatus
900 includes an image reading apparatus 951 provided with a scanner unit 955 and an
image sensor 954, an image forming portion 902 to form an image on a sheet, a two-side
reversing device 953, and a platen glass 952. In addition, a document feeder 950 for
feeding documents to the platen glass 952 is provided on the top face of the image
forming apparatus main body 901.
[0035] The image forming portion 902 includes a cylindrical photosensitive drum 906, a charging
device 907, a developing device 909, a cleaning device 913, and in addition, a fixing
device 912 and a pair of discharging rollers 914 are disposed downstream of the image
forming portion 902. Also, the image forming apparatus main body 901 is connected
to a stacker 100, which is a sheet stacking apparatus for stacking sheets, on which
images are formed, discharged from the image forming apparatus main body 901. A controller
960 controls the image forming apparatus main body 901 and the stacker 100.
[0036] Next, an image forming operation of the image forming apparatus main body 901 configured
as above will be described.
[0037] When an image forming signal is output from the controller 960, firstly a document
is placed on the platen glass 952 by the document feeder 950 and the document image
is read by the image reading device 951. Digital data obtained through reading is
input to an exposure unit 908, by which light according to the digital data is irradiated
onto the photosensitive drum 906.
[0038] On this occasion the surface of the photosensitive drum 906 is uniformly charged
by the charging device 907. When light is irradiated as described above, an electrostatic
latent image is formed on the surface of the photosensitive drum. Through development
of the electrostatic latent image by the developing device 909, a toner image is formed
on the surface of the photosensitive drum.
[0039] In the meanwhile, when a sheet feeding signal is output from the controller 960,
firstly sheets P, which are set in cassettes 902a, 902b, 902c, 902d and 902e, are
conveyed to the registration roller 910 through the feeding rollers 903a, 903b, 903c,
903d and 903e, and a pair of conveying rollers 904.
[0040] Then sheets P are conveyed by the registration roller 910 to a transfer portion which
includes a transfer-separation charging device 905 in such a timing that the leading
edge of a sheet is aligned with the leading edge of the toner image on the photosensitive
drum 906. Then, in the transfer portion, a transfer bias is applied to the sheet P
by the transfer-separation charging device 905, and thus the toner image on the photosensitive
drum 906 is transferred to the sheet.
[0041] Subsequently, the sheet P on which a toner image was transferred is conveyed to the
fixing device 912 by a conveying belt 911, and thereafter the toner image is thermal-fixed
while conveying in the condition being nipped between a heating roller and a pressure
roller of the fixing device 912. Meanwhile foreign substances such as residual toner
not transferred to the sheet but stuck onto the photosensitive drum 906 are scraped
off the drum by a blade of the cleaning device 913. Consequently the surface of the
photosensitive drum 906 is cleaned to be ready for the next image formation operation.
[0042] The fixed sheet is conveyed to the stacker 100 as it stands by the discharging roller
914 or conveyed to the two-side reversing device 953 by a flapper 915 to perform an
image forming process again.
[0043] In the meanwhile, the stacker 100 is provided with a top tray 107 on the top face
thereof for stacking the sheets discharged from the image forming apparatus main body
901. The stacker 100 also performs skew feed correction and lateral registration correction
(positional correction in the direction intersecting the conveying direction) of the
sheets fed from the image forming apparatus main body 901. In addition, the stacker
100 includes a grouping portion 300 where sorting in the shift mode, which is described
later, is carried out.
[0044] Moreover the stacker 100 includes a stacking portion 400 provided with a stack tray
401 on which sheets are stacked, and a top tray switching flapper 103, which directs
sheets conveyed into the stacker 100 toward the top tray 107 or toward the stacking
portion 400. The configurations of the grouping portion 300 and the stacking portion
400 will be described later.
[0045] Fig. 2 is a block diagram illustrating a configuration of the controller 960. The
controller 960 has a CPU circuit portion 206, which includes a CPU (not shown), a
ROM 207 and a RAM 208. The controller 960 controls comprehensively, through the control
program stored in the ROM 207, a DF (document feeding) controlling portion 202, an
operating portion 209, an image reader controlling portion 203, an image signal controlling
portion 204, a printer controlling portion 205, and a stacker controlling portion
210. The RAM 208 holds the control data temporarily and is utilized as a working area
for computing operation required for control.
[0046] The DF (document feeding) controlling portion 202 performs drive control of the document
feeding device 950 based on an instruction from the CPU circuit portion 206. The image
reader controlling portion 203 performs drive control of the scanner unit 955 and
image sensor 954 disposed in the image reading device 951 and transmits analogue image
signals output from the image sensor 954 to the image signals controlling portion
204.
[0047] The image signal controlling portion 204 converts the analogue image signals from
the image sensor 954 to digital signals and thereafter performs various processes.
The digital signals are converted to video signals and output to the printer controlling
portion 205.
[0048] The image signal controlling portion 204 also performs various processes for the
digital image signals input from the computer 200 or from outside via an external
I/F 201 and converts the digital image signals to video signals to output the video
signals to the printer controlling portion 205. Note that the processes through the
image signals controlling portion 204 are controlled by the CPU circuit portion 206.
[0049] The printer controlling portion 205 drives the exposure unit 908 via an exposure
controller (not shown) based on the input video signals. The operating portion 209
includes a plurality of keys for setting various functions regarding image formation
and a displaying portion for displaying the information indicating the setting state.
The operating portion 209 also outputs key signals corresponding to each key operation
to the CPU circuit portion 206 and displays the corresponding information on the display
portion based on the signals from the CPU circuit portion 206.
[0050] The stacker controlling portion 210 is mounted in the stacker 100 and performs a
driving control of the whole stacker through information communication with the CPU
circuit portion 206.
[0051] Next, a basic control in the stacker controlling portion 210 of the stacker 100 will
be described referring to Fig. 1 and a flowchart of Fig. 3.
[0052] The sheet P discharged from the image forming apparatus main body 901 is conveyed
into the internal portion by a pair of entrance rollers 101 of the stacker 100 and
conveyed to the top tray switching flapper 103 by a pair of conveying rollers 102.
[0053] Before the sheet is conveyed, sheet information, such as sheet size, sheet type,
where to discharge the sheet and the like have been transmitted to the stacker controlling
portion 210 from (the CPU circuit portion 206 of) the controller 960 in the image
forming apparatus main body 901.
[0054] Here, the stacker controlling portion 210 determines where to discharge the sheet
which has been conveyed from the controller 960 (S101). If where to discharge the
sheet is to the top tray 107 (S110), the top tray switching flapper 103 is driven
(S111) via a solenoid (not shown) to move to the position as illustrated in Fig. 1.
Consequently, the sheet P is guided to the pair of conveying rollers 104 and 105,
after which the sheet is discharged to the top tray 107 by the top tray discharging
roller 106 (S112), then stacked.
[0055] If the sheet is to be discharged to the stack tray 401 of the stacking portion 400
(S120), the top tray switching flapper 103 is moved to the dotted line position by
a solenoid (not shown). Consequently, the sheet conveyed by the pair of conveying
rollers 102 passes between the pairs of conveying rollers 108, 109, 110, and through
a nip portion between a large roller 111 and the rollers 111a, 111b, 111c. Further
the sheet passes through the conveying roller 112, the grouping portion 300 and the
nip portion between the large roller 113 and the rollers 113a, 113b, 113c, thereafter
the sheet is discharged to the stacking tray 401 (S121) by the discharging rollers
114, and then stacked.
[0056] The grouping portion 300, which corrects skew feed and lateral registration of the
sheets conveyed from the image forming apparatus main body 901 as well as providing
a space for a sorting operation in the shift mode, which is described later, is arranged
between the conveying rollers 112 and the large roller 113 as illustrated in Fig.
1.
[0057] Here, as indicated by the white arrow in Fig. 4 that is a view looking in the direction
indicated by the arrow X1 of Fig. 1, the grouping portion 300 is fixed to a timing
belt 303 and is provided with first and second guides 301, 302, which are movable
symmetrically with respect to the center line of the sheet conveying direction.
[0058] On the opposing side surfaces of the first and second guides 301 and 302, guide portions
301A and 302A are formed, which include a bottom surface supporting the lower surface
of the sheet P and a ceiling surface restricting the upward movement of the sheet
P, and the abutting surfaces 301a and 302a against which the side edges of the sheet
P abut.
[0059] Then, when the sheet P is conveyed, the first and second guides 301 and 302 are in
standby positions having the abutting surfaces 301a and 302a opened wider apart than
the dimension of the sheet by a distance L from each side edge of the sheet depending
on the sheet size in a condition that the center line of the abutting surfaces 301a,
302a are aligned with the center line of the sheet conveying direction.
[0060] The grouping portion 300 includes first and second oblique-feed rollers 304a and
305a that are inclined so that the sheet P is fed obliquely toward the first guide
side, and includes the third and fourth oblique-feed rollers 304b and 305b that are
inclined so that the sheet P is fed obliquely toward the second guide side. Rollers
306a and 307a are the first and second rollers that are selectively brought into contact
with the first and second oblique-feed rollers 304a and 305a so as to nip the sheet
P. Rollers 306b and 307b are the third and fourth rollers that are selectively brought
into contact with the third and fourth oblique-feed rollers 304b and 305b so as to
nip the sheet P.
[0061] Incidentally, the first to the fourth oblique-feed rollers 304a, 305a, 304b and 305b
are made of rubber or sponge of low coefficient of friction having such property that
slipping on the sheet P causes no damage under a predetermined load. The first to
the fourth rollers 306a, 307a, 306b and 307b are arranged to be brought into contact
with the first to the fourth oblique-feed rollers 304a, 305a, 304b and 305b selectively
by solenoids (not shown).
[0062] In the grouping portion 300 configured as described above, the sheet P conveyed by
the conveying roller 112 is now conveyed by the oblique-feed rollers 304 and 305,
having both edges of the sheet pass within the first and second guide portions 301
and 302.
[0063] Here, the grouping portion 300 conveys the sheet P while shifting the sheet P toward
the first guide side or the second guide side, thereby correcting skew feed of the
sheet P and restricting the position of the sheet P in the width direction.
[0064] For example, in order to shift the sheet P toward the first guide side, the first
and second rollers 306a and 307a are brought into contact with the first and second
oblique-feed rollers 304a and 305a, and the third and fourth rollers 306b and 307b
are kept separated from the third and fourth oblique-feed rollers 304b and 305b.
[0065] Accordingly, a conveying force in the direction indicated by the hatched arrow in
Fig. 4 is applied to the sheet P by the first and second oblique-feed rollers 304a
and 305a. The guide portion 301A of the first guide 301 restricts the movement of
the sheet in upper and lower directions at the edge of the first guide side, and the
sheet moves while abutting on the abutting surface 301a. As a result, the skew feed
of the sheet P is corrected and also the position in the width direction can be set
by the abutting surface 301a, as shown by the dotted line.
[0066] When the sheet P is shifted toward the second guide side, the third and fourth rollers
306b and 307b are brought into contact with the third and fourth oblique-feed rollers
304b and 305b, and the first and second rollers 306a and 307a are kept separated from
the first and second oblique-feed rollers 304a and 305a.
[0067] Accordingly, a feeding force is applied to the sheet P by the third and fourth oblique-feed
rollers 304b and 305b. The guide portion 302A of the second guide 302 restricts the
movement of the sheet in upper and lower directions at the edge of the second guide
side, and the sheet P moves while abutting on the abutting surface 302a. As a result,
skew feed of the sheet P is corrected and also the position in the width direction
can be set by the abutting surface 302a.
[0068] According to the arrangement described so far, each sheet bundle can be shifted in
different direction by controlling the contact and separation of the first to the
fourth rollers 306a, 307a, 306b and 307b. The maximum shift amount between two sheet
bundles is thus 2L.
[0069] Next, the configuration of the stacking portion 400 for containing a large volume
of sheets will be described referring to Fig. 5, which is a view looking in the direction
indicated by the arrow X2 of Fig. 1, Fig. 6, which is a view looking in the direction
indicated by the arrow X3 of Fig. 1 and Fig. 7 which is a cross-sectional view taken
along the line VII-VII of Fig. 5.
[0070] The stacking portion 400, as illustrated in Figs 5 to 7, includes a stack tray 401,
which is a sheet stacking portion for stacking sheets horizontally, a leading edge
stopper 404 and first and second side stoppers 410, 420.
[0071] The stack tray 401 is arranged to be movable in up and down directions (capable of
lifting and lowering) by a lift motor, which is a lifting and lowering unit (not shown).
The stack tray 401 is disposed below the discharging roller 114, which discharges
the sheet P to the stack tray 401 and the sheet surface detection sensor 403 (shown
in Figure 1) detects the sheet surface position of the stack tray 401. The height
position of the stack tray 401 is controlled by the stacker controlling portion 210
so that the top position of the sheet in the stack tray 401 always remains the same
based on the output of the sheet surface position detecting sensor 403.
[0072] Four casters 402 are mounted on the bottom face of the stack tray 401 so that the
whole stack tray 401 can be pulled out from the stacker 100 to be conveyed when a
job is completed. Fig. 8 illustrates a state of sheets P of large size stacked in
a shiftless manner. A handle 450 is attached to the stack tray 401 to improve conveyance.
[0073] The leading edge stopper 404 is to abut on and restrain the leading edge of the sheet
discharged to the stack tray 401 in the direction indicated by the arrow in Figs.
5 and 7. The leading edge stopper 404 is supported by the two slide rails 405 above
the stack tray 401 and disposed between the two slide rails 405. Also the leading
edge stopper 404 is fixed to a belt 406, which can be moved in the sheet conveyance
(discharging) direction by a motor 407. Therefore, if the motor 407 is rotated in
forward and reverse directions, the leading edge stopper 404 moves in the sheet conveying
direction and the reverse direction.
[0074] The leading edge stopper 404 includes an edge plate 404a having a perpendicular surface
to engage the sheet edge discharged to the stack tray 401 and a fixing member 404b,
which has an L-like shape connecting the belt 406 and the edge plate 404a.
[0075] The leading edge plate 404a, as illustrated in Fig. 6, is supported by a fixing member
404b via four bushes 404c so as to be slidable vertically within a predetermined area.
Owing to this arrangement, the leading edge plate 404a abuts on the stack tray surface
by gravity when no sheet is stacked on the stack tray 401. Also the leading edge plate
descends as the stack tray 401 descends.
[0076] A sensor 408 detects the position of the leading edge stopper 404. The stacker controlling
portion 210 drives the motor 407 based on the size information of the sheet to be
stacked to move the leading edge stopper 404 appropriately.
[0077] As illustrated in Fig. 1 or Fig. 11, which will be described later, a trailing edge
guide 115 is mounted opposite to the leading edge stopper 404 immediately below the
discharging roller 114. Consequently, the position of the sheets P contained in the
stack tray 401 in the conveying direction is regulated by a span between the leading
edge stopper 404 and an abutting face 115a of the trailing edge guide 115 illustrated
in Fig. 11 to be described later.
[0078] The first and second side stoppers 410 and 420 are provided upstream of the leading
edge stopper 404 in the sheet discharging direction and make up a pair of side edge
regulating members to align the position in the width direction of both edges of the
sheet discharged to the stack tray 401.
[0079] The first and second side stoppers 410 and 420 are supported by two slide rails 430
above the stack tray 401 and are fitted to a belt 431 driven by the motor 432 so as
to be movable in the width direction getting nearer to or further away from each other.
[0080] The stacker controlling portion 210 drives the motor 432 based on the sheet size
information to move the first and second side stoppers 410 and 420 appropriately corresponding
to the signals from the sheet discharging sensor 116.
[0081] Here, the first and second side stoppers 410, 420 are provided with the external
plates 411, 421, and the internal plates 412, 422 having vertical surfaces to align
the sheet side edges. The respective gaps between the external plates 411, 421 and
the internal plates 412, 422, illustrated in Fig. 6, are equivalent to the shift amount
2L in the grouping portion 300.
[0082] The external plates 411, 421 are supported, similarly to the leading edge plate 404a
of the leading edge stopper 404 as described above, by the first and second side stoppers
410, 420 so as to be slidable vertically within a predetermined area via sliding means
(not shown). Owing to this arrangement, the external plates 411, 421 abut on the stack
tray surface by gravity when no sheet is stacked on the stack tray 401. Also the external
plates 411, 421 descend as the stack tray 401 descends.
[0083] The internal plate 412, 422, which are aligning members, are arranged to lift and
lower via solenoids 413, 423 and links (not shown). Then, the internal plates 412,
422 are arranged to be supported by a support unit including the solenoids 413, 423
and the links so as to be capable of descending by a certain distance accompanied
by descending of the stack tray 401 in a state that the internal plates 412, 422 are
laid on the sheet bundles stacked in the sheet tray 401. Note that in the exemplary
embodiment the descending distance of the internal plates 412, 422 are shorter than
that of the other aligning members of external plates 411, 421 and the leading edge
plate 404a, which is an abutting member of the leading edge stopper 404.
[0084] Due to this arrangement, as described later, when the number of the stacked sheets
becomes 40, for example, and then the stack tray 401 descends corresponding to the
number of sheets stacked, the internal plates 412, 422 become released from the sheets
in the stack tray.
[0085] It should be noted that in Fig. 6 the internal plate (hereinafter referred to as
the first internal plate) 412 in the side of the first side stopper is positioned
lower due to a switched-OFF state of the solenoid 413, in which state the internal
plate 412 abuts on the stack tray surface if there is no sheet on the stack tray 401,
and abuts on the sheet if there are sheets. On the contrary, the internal plate (hereinafter
referred to as the second internal plate) 422 in the side of the second side stopper
is positioned higher due to a switched-ON state of the solenoid 423.
[0086] Here, when the sheet P is to be shifted with respect to the first guide 301 in the
aforementioned grouping portion 300, the first internal plate 412 is placed at the
lower position, which is an aligning position abutting on the side edge of the sheet
P to align the width direction position. Meanwhile the second internal plate 422 is
in a higher position, which is an upper retreat position. Thereby, the sheet that
is shifted with respect to the first guide 301 in the grouping portion 300 is stored
between the first internal plate 412 and the external plate 421 (hereinafter referred
to as the second external plate) of the second side stopper 420.
[0087] On the contrary, when the sheet P is stored, which was shifted with respect to the
second guide 302 in the grouping portion 300, the first internal plate 412 is placed
at the higher position and the second internal plate 422 is placed at the lower position.
Thereby the sheets are stored between the external plate 411 (hereinafter referred
to as the first external plate) of the first side stopper 410 and the second internal
plate 422.
[0088] Next, the sheet stacking operation to the stacking portion 400 in the stacker 100
will be described. Note that the stacker 100 includes two modes in the present embodiment,
which are a shiftless mode where all the sheets in the stack tray are stacked at the
same position and a shift mode where the sheets discharged to the stack tray are stacked
while being shifted (displaced) in the width direction for every bundle of sheets.
[0089] Firstly, the sheets stacking operation in the shiftless mode will be described.
[0090] When the shiftless mode is selected, the shift direction at the grouping portion
300 remains the same and an operator can select between a shift to the first guide
side and to the second guide side. Here the shift to the first guide side will be
described.
[0091] When the shift to the first guide side is selected by the operating portion 209 illustrated
in Fig. 2, the stacker controlling portion 210 outputs a control signal to the grouping
portion 300 and the stacking portion 400 via the CPU circuit portion 206 before the
sheet is conveyed to the stacker 100.
[0092] Based on this control signal, the grouping portion 300 makes the first and second
guides 301, 302 stand by at a wider position by a dimension L with respect to the
sheet size (width) respectively. In addition, the first and second rollers 306a, 307a,
which are illustrated in Fig. 4, are made to be in contact with the first and second
oblique-feed rollers 304a, 305a and the third and fourth rollers 306b, 307b are kept
to stand by away from the third and fourth oblique-feed rollers 304b, 305b.
[0093] In the stacking portion 400, the first and second side stoppers 410, 420 are kept
to stand by, as illustrated in Fig. 6, such that the first and second external plates
411, 421 are positioned at a standby position expanded slightly (by 2 mm) wider than
2L with respect to the sheet size (a length in sheet width direction) W, respectively.
Further, the first internal plate 412 is placed to stand by at the lower position
and the second internal plate 422 is placed to stand by at the higher position.
[0094] The leading edge stopper 404 is kept to stand by at a standby position in which the
distance between the leading edge plate 404a and the abutting surface 115a of the
trailing edge guide 115 is expanded slightly (by 2 mm) wider than the sheet size (a
sheet length in sheet conveying direction). At that time, the stack tray 401 stands
still in a state that the sheet face or the stack tray face if there is no sheet stacked
is detected by the sheet surface detecting sensor 403 shown in Figure 1.
[0095] Next, after the first and second guides 301, 302 and the first and second side stoppers
410, 420 are moved to the standby position (initial position), the sheets are conveyed
to the stacker 100. The sheets conveyed to the stacker 100 like this are conveyed
to the grouping portion 300 by the conveying roller 112 after passing through the
pairs of conveying rollers 108, 109, 110 by switching of the top tray switching flapper
103.
[0096] Then, in the grouping portion 300, as illustrated in Fig. 9, the sheet P is nipped
between the first and second oblique-feed rollers 304a, 305a and the first and second
rollers 306a, 307a, and conveyed in a skew feed manner to abut on the abutting surface
301a of the guide portion 301A on the first guide side. Thereby the sheet P is conveyed
with respect to the abutting surface 301a, being corrected in the skew feed and the
position of the width direction.
[0097] Thereafter, as illustrated in Fig 10A, the sheet P is discharged to the stack tray
401 by the discharging roller 114, entering between the second external plate 421
and the first internal plate 412. On this occasion, as described already, the leading
edge plate 404a of the leading edge stopper 404, the second external plate 421 and
the first internal plate 412 are abutted against the stack tray surface.
[0098] Therefore, the leading edge of the discharged sheet P is stopped by the leading edge
plate 404a of the leading edge stopper 404 as illustrated in Fig. 11. Also, the both
side edges of the sheet P are confined by the second external plate 421 and the first
internal plate 412, and the leading edge and trailing edge of the sheet P in the sheet
discharging direction are confined by the leading edge plate 404a of the leading edge
stopper 404 and the abutting surface 115a of the trailing edge guide 115.
[0099] Thereafter, the stacker controlling portion 210 drives the motor 432 to move the
first and second side stoppers 410, 420 based on a detection signal of the sheet discharging
sensor 116, which is disposed in a vicinity of the discharging roller 114 as illustrated
in Fig. 11, for detection of the sheet P.
[0100] Owing to this, the first and second side stoppers 410, 420, which are disposed upstream
of the leading edge stopper 404 in the sheet conveying direction, moves toward one
another (in the direction getting closer to the sheet P) by 2 mm respectively from
the standby position, as illustrated by the arrows in Fig. 10B. As a result, the distance
between the second external plate 421 and the first internal plate 412 becomes equal
to the sheet size (width) and the side edges of the sheet P are brought into contact
with the plates, and thereby an aligning operation of the discharged sheet P in the
width direction can be performed.
[0101] After the width direction aligning operation of the sheet described above has been
performed, the first and second side stoppers 410, 420 move to the standby position,
which is a position expanded wider by 2 mm again to be ready for the next discharged
sheet.
[0102] Subsequently, as illustrated by an arrow in Fig. 12, the leading edge stopper 404
disposed downstream in the sheet conveying (discharging) direction moves upstream
(direction getting closer to the sheet P) by 2 mm actuated by the motor 407. Due to
this, the distance between the leading edge plate 404a of the leading edge stopper
404 and the abutting surface 115a of the trailing edge guide 115 becomes equal to
the length of the sheet P in the conveying direction, and thus an aligning operation
of discharged sheets P in the sheet conveying direction can be performed.
[0103] After the sheet aligning operation in the sheet conveying direction is performed
in this way, the leading edge stopper 404 moves again to the standby position, which
is a position expanded wider by 2 mm, to be ready for subsequently discharged sheets.
[0104] Thus, the above-mentioned operation is repeated every time a sheet is discharged
until the last sheet is discharged, and thereby a required number of sheets P are
stacked on the stack tray 401. Until the required number of sheets P are stacked,
the stacker controlling portion 210 controls the height position of the top sheet
surface in the stack tray 401 so as to be a detecting position of the sheet surface
detection sensor 403.
[0105] As stacking progresses, as illustrated in Fig. 13, the leading edge plate 404a of
the leading edge stopper 404, the second external plate 421 and the first internal
plate 412 are getting away from the face of the stack tray 401. However, the leading
edge plate 404a and the second external plate 421 can move downward by gravity within
the sliding area as described above.
[0106] Therefore even if there is a small variation in the height position of the stacked
sheet surface in the stack tray 401, it is possible to move securely the aligned sheets
P downward together with the stack tray 401, keeping the alignment of the sheets.
[0107] When the shift toward the second guide side is selected, the first and second rollers
306a, 307a illustrated in Fig. 4 are separated from the first and second oblique-feed
rollers 304a, 305a. The third and fourth rollers 306b, 307b are brought into contact
with the third and fourth oblique-feed rollers 304b, 305b. Further in the stacking
portion 400, the internal plate (hereinafter referred to as the first internal plate)
412 of the first side stopper side of the first and second side stoppers 410, 420
is located in higher position for standby, and the second internal plate 422 is in
lower position for standby.
[0108] Incidentally, in the present embodiment, the aligning operation of the sheets P is
not to be done in both directions simultaneously for the sheet conveying direction
and the width direction, but one direction at a time, which enables the sheet to follow
the aligning surface with ease and to correct skew of the sheets securely.
[0109] Furthermore, in the present embodiment as described above, the aligning operation
by the first and second side stoppers 410, 420, which are disposed upstream of the
leading edge stopper 404 in the sheet conveying direction, is arranged to be performed
first, and the aligning operation by the leading edge stopper 404 is performed next.
[0110] The aligning operation by the first and second side stoppers 410, 420 is performed
first as described above, so that the first and second side stoppers 410, 420 can
be moved to the standby position before a subsequent sheet is discharged to the stack
tray 401.
[0111] In addition, in the present embodiment, the first and second side stoppers 410, 420
are arranged to move away from the sheet before the aligning operation by the leading
edge stopper 404 is completed.
[0112] By such an arrangement the subsequent sheet can be discharged to the stack tray 401
with a timing not to collide against the leading edge stopper 404 after moving to
the aligning position. Accordingly the discharge interval of the sheets P to the stack
tray 401 can be shortened and the sheets P can be stacked steadily with high speed
and high precision.
[0113] As described so far, the first and second side stoppers 410, 420 are arranged to
move away from the sheet after the first sheet alignment but before the aligning operation
by the leading edge stopper 404 is completed. Due to this arrangement, the sheets
can be stacked steadily with high speed and high precision. Owing to this, it is possible
to cope with an image forming apparatus 900, which has shorter time intervals between
discharging of sequential sheets, thereby providing higher productivity.
[0114] Next, the sheet stacking operation in the shift mode will be described.
[0115] When the shift mode is selected, for example, in order to shift the initial sheet
bundle to be stacked in the stack tray 401 to the first guide side, the sheets are
stacked on the sheet tray 401 in the same way as the stacking operation for the shiftless
mode as described above.
[0116] Next, when a subsequent sheet bundle is shifted to the second guide side and stacked
on that side, immediately after the last sheet of the previous sheet bundle passes,
the first and second rollers 306a, 307a, illustrated in Fig. 4 are separated from
the first and second oblique-feed rollers 304a, 305a. At the same time the third and
fourth rollers 306b, 307b are brought into contact with the third and fourth oblique-feed
rollers 304b, 305b.
[0117] In the stacking portion 400, as illustrated in Fig. 14, the first and second internal
plates 412, 422 of the first and second side stoppers 410, 420 are arranged to be
in a higher position and a lower position respectively for standby by changing over.
On this occasion, the second internal plate 422, which has moved to the lower position,
is laid on the sheet bundle PA shifted to and stacked on the first guide side.
[0118] Next, after the first and second guides 301, 302, and the first and second side stoppers
410, 420 move to the standby position (initial position), the sheets are conveyed
to the grouping portion 300 by the conveying roller 112.
[0119] In the grouping portion 300, as illustrated in Fig. 15, the sheet P is nipped for
the oblique-feed by the third and fourth oblique-feed rollers 304b, 305b and the third
and fourth rollers 306b, 307b, thereafter the sheet abuts on the abutting surface
302a of the guide portion 302A of the second guide side. Thereby, the skew feed and
the width direction position are corrected and the sheet P is conveyed with reference
to the abutting surface 302a.
[0120] Thereafter, the sheet P1 discharged by the discharging roller 114, as illustrated
in Fig. 16, enters between the first external plate 411 and the second internal plate
422 to be stacked on the top surface of the sheet bundle PA shifted to and stacked
on the first guide side.
[0121] At that time, the leading edge plate 404a of the leading edge stopper 404 and the
second external plate 421 abut on the side surfaces of the sheet bundle PA, and the
second internal plate 422 abuts on the top surface of the sheet bundle PA. Therefore
the leading edge of the discharged sheet P1 is stopped by the leading edge plate 404a
of the leading edge stopper 404.
[0122] Thereby, when the sheets are discharged to the stack tray 401, the sheets are surrounded
by the first external plate 411 and the second internal plate 422 for the side edges
of the sheets P1, and by the leading edge plate 404a of the leading edge stopper 404
and the abutting surface 115a of the trailing edge guide 115 for the leading and trailing
edges of the sheets P1 in the sheet discharging direction.
[0123] On this occasion the second internal plate 422 is laid on the already-stacked sheet
bundle. Therefore, when the aligning operation is performed, thereafter, by the first
and second side stoppers 410, 420 as described above, the second internal plate 422
slides on the already-stacked sheet bundle and the uppermost sheet Pa of the already-stacked
sheet bundle PA is fed together with the second internal plate 422 in association
with the slide of the second internal plate 422 as illustrated in Fig. 16, resulting
in disordering the alignment of the sheet P.
[0124] Since the moving distance of the first and second side stoppers 410, 420 is 2 mm,
one aligning operation may deviate the uppermost sheet (hereinafter referred to as
the already-stacked uppermost sheet) Pa in the already-stacked sheet bundle PA by
2 mm in the worst case. Then, repeated aligning operations increase the deviation
amount.
[0125] In order to avoid such deviation, the aligning operation in the width direction is
performed collectively only once for each first predetermined number of stacked sheets,
before the second internal plate 422 is separated from the uppermost sheet Pa of the
already-stacked sheets due to descent of the stack tray 401 accompanied with stacking
of the sheet P1. Note that, in the present embodiment, the first predetermined number
of the stacked sheets is 20, and as the number of the stacked sheets increases, the
stack tray 401 descends accordingly. Accompanying with this, the number of sheets
at which the second internal plate 422 is separated from the already-stacked uppermost
sheet Pa is to be a number of sheets exceeding 40 sheets as described above.
[0126] In other words, in the present embodiment, the aligning operation by the first and
second side stoppers 410, 420 is performed collectively every time each 20 sheets
are stacked on the stack tray 401. In addition, after the second internal plate 422
is separated from the already-stacked uppermost sheet Pa by the stack tray 401, on
which 40 sheets have been stacked, descending, the aligning operation is performed
every time the second predetermined number of sheets is discharged. In the present
embodiment, after the second internal plate 422 is separated from the already-stacked
uppermost sheet Pa, the aligning operation is performed every time a sheet is discharged.
[0127] According to such arrangement, sheets to be shifted to the second guide side and
discharged to the stack tray 401 are aligned only by the aligning operation of the
leading edge stopper 404 in the sheet conveying direction every time one sheet is
stacked, up to 19 sheets. At this time, the first and second side stoppers 410, 420
stand still at the standby position.
[0128] As illustrated in Fig. 17A, when the 20th sheet is discharged, the first and second
side stoppers 410, 420 move toward one another (getting closer to the sheet) by 2
mm respectively actuated by the motor 432. Thereby, the distance between the first
external plate 411 and the second internal plate 422 becomes equal to the width of
the sheet P, hence the aligning operation in the width direction can be performed
collectively for the sheet bundle PB of the discharged 20 sheets.
[0129] After the aligning operation of the sheet bundle PB in the width direction, the first
and second side stoppers 410, 420 move to the standby position, which is a position
expanded by 2 mm, again to be ready for the subsequent discharged sheet. Thereafter,
the aligning operation for the sheet conveying direction of the sheet bundle PB by
the leading edge stopper 404 as described above is performed.
[0130] Such collective aligning operation is also applied for the subsequent 20 sheets to
be discharged, and a sheet P40 exceeding 40 sheets is stacked in due course as illustrated
in Fig. 17B. Since the number of stacked sheets at which the second internal plate
422 is separated from the already-stacked uppermost sheet Pa exceeds 40, and thus
when the sheet P40 exceeding 40 sheets is stacked and the stack tray 401 descends,
the second internal plate 422 is separated from the already-stacked uppermost sheet
Pa.
[0131] After the second internal plate 422 is separated from the already-stacked uppermost
sheet Pa, even when the aligning operation by the first and second side stoppers 410,
420 is performed, the internal plate 422 never slides on the already-stacked uppermost
sheet Pa to feed the already-stacked uppermost sheet Pa in association with the sliding
of the internal plate 422.
[0132] When the sheet P after the 41st onwards is discharged, the aligning operation by
the first and second side stoppers 410, 420 and the aligning operation by the leading
edge stopper 404 are performed every time a sheet is discharged just like the case
of the 20th sheet and the 40th sheet, since the second internal plate 422 has been
separated from the already-stacked uppermost sheet Pa.
[0133] Also the last sheet in a case where the number of sheets in the sheet bundle PB is
not more than 40, the sheet is stacked through the aligning operation by the first
and second side stoppers 410, 420 and the aligning operation by the leading edge stopper
404 just like the case of 20th sheet and from the 40th sheet onward.
[0134] When stacking with a shift to the second guide side is completed, and there are still
sheet bundles to be stacked, stacking is continued through changing to the stacking
with a shift to the first guide side again. In this case again, the first and second
side stoppers 410, 420 perform the aligning operation every 20 sheets up to the first
40 sheets. Such operations as described above are repeated up to the final bundle
to stack the required number of sheets on the stack tray 401.
[0135] Fig. 19 is a flowchart of the aligning operations of the first and second side stoppers
410 and 420. As shown in Fig. 19, when the sheet discharging sensor 116, which detects
the coming of a sheet, is turned on (S101), the stacker controlling portion 210 counts
a number of discharged sheets (S120). With this, the stacker controlling portion 210
can calculate the number of sheets stacked on a sheet bundle previously stacked and
displaced on the stack tray 401.
[0136] The stacker controlling portion 210 discriminates whether or not the counted number
of stacked sheets is 40 or less (S103). When the counted number of stacked sheets
is 40 or less, the stacker controlling portion 210 discriminates whether or not a
number of stacked sheets is 20 (S104). When the number of stacked sheets is not 20,
the stacker controlling portion 210 discriminates whether or not the number of stacked
sheets is 40 (S105). When the number of stacked sheets is not 40, the stacker controlling
portion 210 discriminates whether or not it is the last sheet (S106). When it is not
the last sheet, the procedure returns to S101. On the other hand, when the stacker
controlling portion 210 discriminates that it is the last sheet, the stacker controlling
portion 210 controls the first and second side stoppers 410 and 420 to perform the
aligning operation (S107). Then, the procedure is ended.
[0137] When the number of stacked sheets is not 40 or less, and when the number of stacked
sheets is 20 or 40, the stacker controlling portion 210 controls the first and second
side stoppers 410 and 420 to perform the aligning operation (S108). Then, after the
aligning operation, the stacker controlling portion 210 discriminates whether or not
it is the last sheet (S109). When it is not the last sheet, the procedure returns
to S101. When it is the last sheet in S109, the procedure is ended.
[0138] When such a configuration as described above is adopted, the number of associated
feedings of the already-stacked uppermost sheet Pa in association with the aligning
operation by the first and second side stoppers 410, 420 is one time only, and the
deviation amount thereof is suppressed down to 2 mm or less, which in general gives
no practical problems.
[0139] As described above, when the internal plates 412, 422 slide on the top surface of
the already-stacked sheet bundle, the aligning operation is performed after a plurality
of sheets has been stacked. Thereby, even when the sheet bundles are stacked with
the sheet bundles being staggered, the sheets can be stacked steadily without disordering
the alignment of the already-stacked sheet bundle.
[0140] It should be noted that the number of sheets to be aligned collectively within the
range of 40 sheets may be altered appropriately depending on aligning performance
of a collective aligning and the deviation amount of the associated feeding of the
already-stacked uppermost sheet Pa. In general, the larger number of sheets to be
collectively aligned, the less deviation amount caused by the associated feedings.
On the contrary, the less number of sheets to be collectively aligned, and the better
aligning performance of a collective alignment is achieved.
[0141] According to the description presented so far, after the second copy (bundle) onwards
in the shift mode, the initial sheets up to 40 sheets are divided into groups of 20
sheets, and the 20 sheets are aligned collectively so that the number of associated
feedings is reduced so that less amount of deviation is obtained.
[0142] However, after the second copy (bundle) onwards in the shift mode, it may be arranged
so that no aligning operation is performed up to 40 sheets. In other words, when the
number of the subsequent bundle to be stacked is less than or equal to 40, the aligning
operation may be performed after all sheets for the subsequent bundle are discharged.
In this case, the distance between the external plates 411, 421 of the first and second
side stoppers 410, 420 and the opposing internal plates 412, 422 is wider than the
sheet size by 2 mm each, which is 4 mm in total.
[0143] Therefore, in this case the sheets may have deviation of this amount as maximum (within
4 mm) on the stack tray. But it is better that the first and second side stopper 410,
420 align the sheets after all sheets are discharged on the stack tray than the first
and second side stopper 410, 420 aligns sheets every time a sheet is stacked on the
stack tray 401. Because the deviation is produced largely beyond 4 mm through moving
the first and second side stoppers 410, 420 together every time a sheet is stacked
on the stack tray 401.
[0144] Also such an arrangement may be adopted that no aligning operation is performed when
the internal plates 412, 422 are laid on a sheet bundle previously stacked after the
second bundle onwards in the shift mode, and the aligning operation is performed every
time the predetermined number of sheets are discharged after the internal plates 412,
422 are separated from the top surface of the sheet bundle previously stacked, accompanying
with the stack tray descending.
[0145] While the present invention has been described with reference to exemplary embodiments,
it is to be understood that the invention is not limited to the disclosed exemplary
embodiments. The scope of the following claims is to be accorded the broadest interpretation
so as to encompass all such modifications and equivalent structures and functions.
STATEMENTS
[0146]
- 1. A sheet stacking apparatus, comprising:
a tray (401) on which sheets are stacked;
aligning means (410, 420) which aligns the sheets stacked on the tray, wherein the
aligning means aligns sheets, stacked on a sheet previously stacked on the tray, with
a displacement in an aligning direction of the aligning means with respect to the
sheet previously stacked; and
changing means (210) which changes an aligning operation of the aligning means based
on whether the number of sheets stacked with the displacement on the sheet previously
stacked is equal to or less than a predetermined number.
- 2. A sheet stacking apparatus according to statement 1, wherein when the number of
sheets stacked on the sheet previously stacked is equal to or less than the predetermined
number, the aligning means performs the aligning operation every time a predetermined
two or more number of sheets are stacked.
- 3. A sheet stacking apparatus according to statement 2, wherein when the number of
sheets stacked on the sheet previously stacked exceeds the predetermined number, the
aligning means performs the aligning operation every time a sheet is stacked.
- 4. A sheet stacking apparatus according to statement 1, wherein the aligning means
aligns sheets on the sheet previously stacked with the aligning means being in contact
with a top surface of the sheet previously stacked, and
a number of sheets exceeding the predetermined number is set as a number at which
the aligning means is positioned such that it does not come in contact with the top
surface of the sheet previously stacked.
- 5. A sheet stacking apparatus according to staement 1, wherein
when the number of the sheets stacked on the sheets previously stacked is less than
or equal to the predetermined number, the aligning means performs the aligning operation
every time a first number of sheets are stacked on the tray;
when the number of the sheets stacked on the bundle of sheets previously stacked exceeds
the predetermined number, the aligning means performs the aligning operation every
time a second number of sheets are stacked on the tray; and
the first number is larger than the second number.
- 6. A sheet stacking apparatus according to any preceding statement, further comprising:
lifting and lowering means which moves the tray so that the position of an uppermost
sheet of the sheets stacked on the tray is held at a constant height; and
support means which supports the aligning means so that the aligning means is lowered
by a predetermined distance with the aligning means being in contact with a top surface
of the sheets previously stacked as the tray is lowered by the lifting and lowering
means.
- 7. A sheet stacking apparatus according to any preceding statement, further comprising
conveying means (112, 300) which conveys sheets to be stacked on the tray,
wherein the conveying means conveys a subsequent sheet to the tray with a position
of the subsequent sheet being changed in an aligning direction of the aligning means
with respect to a position of a preceding sheet conveyed.
- 8. A sheet stacking apparatus, comprising:
a tray (401) on which sheets are stacked;
aligning means (410, 420) which aligns the sheets stacked on the tray, wherein the
aligning means aligns sheets, stacked on a sheet previously stacked on the tray, with
a displacement in an aligning direction of the aligning means with respect to the
sheet previously stacked; and
changing means (210) which changes the aligning operation of the aligning means between
a first state in which the aligning means is in contact with the top surface of the
sheet previously stacked and a second state in which the aligning means is spaced
away from the top surface of the sheet previously stacked.
- 9. An image forming apparatus, comprising:
an image forming unit (100) which forms an image on a sheet; and
a sheet stacking apparatus as claimed in any preceding claim to stack a sheet conveyed
after an image is formed on the sheet by the image forming portion.